Process for producing tufted structures



Aug. 25, 1964 M. v. SUSSMAN 3,145,446

PROCESS FOR PRODUCING TUFTED STRUCTURES Filed Nov. 21, 1962 2Sheets-Sheet 1 INVENTOR MARTIN VICTOR SUSSMAN BY 2M ZTM r ATTORNEY Aug.25, 1964 M. v. SUSSMAN 3,145,446

PROCESS FOR PRODUCING TUFTED STRUCTURES Filed NOV. 21, 1962 2Sheets-Sheet 2 r K r INVENTOR MARTIN VICTOR SUSSMAN ATTORNEY UnitedStates Patent Filed Nov. 21, 1962, Ser. No. 239,143 19 Claims. (Cl.28-42) This invention relates to a novel process for the production oftufted structures.

Tufted or pile surface structures have been made in the past by avariety of processes. Commonly, such structures are made by aneedle-tufting operation in which a series of reciprocating needles areused to force loops of yarn through a ground fabric, generally burlap orthe like, the loop being held in place on the underside of the fabric bya hook or like element until the needle passes on to the next tuftingpoint. Thus, a loop of the pile-forming yarn is inserted at each pointpenetrated by the needle. Because of the complexity of the tuftingequipment, such tufting processes are expensive and are not adaptable tothe production of a variety of tufted products.

An object of the present invention is to provide a novel, rapid,inexpensive and versatile tufting process. A further object of thisinvention is to provide a process for tufting continuous filaments,yarns, threads, and like filamentary strands into an aperturedstructure. A further object of this invention is to provide novel tuftedstructures. Other objects of this invention will become ap parent in thecourse of the following specification and claims.

The objects of this invention are accomplished by utilizing a highvelocity fluid to insert tuft loops of a filamentary strand into theopenings of a backing material. Preferably, an air jet or likefluid-propelling device is used to simultaneously convey the filamentarystrand and to propel it through adjacent successive openings in thebacking material.

Accordingly, the present invention provides a process for the continuousproduction of tufted structures comprising propelling a filamentarystrand by means of a high velocity fluid into contact with an aperturedbacking material, said fluid having sufiicient velocity to force thestrand beyond the plane of the backing material, and employing relativelateral movement between the strand and the backing material to causethe strand to alternately penetrate the openings of the backing materialand suspend itself from the walls of the openings, thereby forming tuftloops in each opening.

In a preferred embodiment of this invention, the tufting process isintegrated with the production and/or processing of filamentary strands.Thus, the filamentary strands may be led directly from a spinning,drawing or like operation to a fluid-propelling device, which latter mayserve to crimp, bulk or otherwise texture the strand in addition topropelling it.

Alternatively, filaments, yarns, and the like originatingfrom Woundbobbins, spools, etc., may be converted into tufted structures by theprocess of this invention.

The tufting process may be carried out to produce tufts in all openingsof the backing member or in a programmed manner to produce a pattern oftufts in selective areas. By varying the rate of relative lateralmovement between the strands and the backing member during production ofa given tufted structure, it is possible to vary the tuft height toproduce textured or sculptured effects.

By filamentary strand is meant any continuous filament, yarn, fiber,thread, roving, fibrillated strand, tow or the like. The filamentarystrands may consist of any Patented Aug. 25., 1964 ice natural orsynthetic, organic or inorganic material, or combinations thereof.

The backing member may be any open mesh, perforated or louveredstructure, consisting of a structural portion defining a plurality ofopenings, the openings being square, rectangular, rhornbic, triangular,circular, etc. Suitable backing materials include burlap and other wovenor knitted fabrics, netting, screening, woven scrims, perforated platesor sheets, honeycomb, an array of wires, yarns, blades and the likearranged to define any shape and/or size openings, etc. The backingmember may be planar or may be preshaped to a 3-dimensional contour forproducing a tufted structure ready for use on a contoured surface.

The fluid propelling device may be any air, steam, or hydraulic jet,which is constructed so as to provide a stream of fluid flowing in adirection concurrent with that of the filamentary strand.

In a further embodiment of this invention, tufts are simultaneouslyproduced on both surfaces of an apertured backing material by regulatingthe velocity of the fluid so as to force a portion of the strandfilaments through the openings to form tufts projecting from the bottomsurface of the backing material, while the remaining strand filamentsloop and form tufts projecting from the top surface of the backingmaterial. Alternately, both sides of the backing material may beprovided with tufts by directing strands into different openings of theapertured structure from opposite sides thereof.

In general, the tufted structures of this invention comprise anapertured tuft-supporting member and a plurality of filamentary strandslooped into and out of the apertures of said member to form tuftsprojecting only from the apertures. In one embodiment of this invention,the tufted structures comprise an open mesh tuftsupporting member and aplurality of tufts formed from filamentary strands projecting only fromthe meshes of said member. structure, the apertures of which are definedby intersecting or crossing linear elements.

In a particular embodiment of this invention, there is provided a tuftedstructure comprising an apertured tuftsupporting member and a pluralityof tuft-forming filamentary strands, the strands being looped into andout of said apertured member to form a plurality of tufts projectingfrom one surface of the apertured member, the strands of each tuft beingshared with those of adjoining tufts in the planar directions of thestructure. This type of tuft sharing is produced by traversing theapertured member with a multi-strand stream or streams along a pathwhich permits the strands to traverse all walls of each cell.

In a still further embodiment of this invention, there is provided aself-supporting unitary tufted structure comprising (l) a permanentbacking member consisting of randomly interlaced continuous filamentarystrands, (2) an intermediate member consisting of an apertured,tuft-supporting member, and (3) a pile portion consisting of a pluralityof tufts formed from filamentary strands suspended from said apertures,the strands of the pile portion being continuous with the strands of thebacking portion. Such products may be made by first forming a tufted.structure and then continuing to deposit filamentary strands on thesurface thereof, until a Web of randomly entangled strands of anydesired thickness is obtained.

If desired, an additional permanent backing may be applied to thenon-tuft side of the products of this invention. Such a backing mayconsist of a non-woven mat, web or the like, fabrics, films, etc., andmay be bonded) thereto by any suitable means.

Tuft height depends upon the force of the fluid driving By open meshmember is meant a the filamentary strand through the apertures of thebacking member, which will vary with the velocity and pressure of thejet fluid; and upon the residence time of the strand in the aperture,which will vary with the velocity of the backing member relative to thestrand feed rate. Tuft height may be controlled by placing a deflectingsurface, hereinafter referred to as a stopper screen beneath andparallel to the apertured member during the tufting process. Thepresence of the stopper screen prevents the strands from traveling thefull distance otherwise provided by the driving force of the fluid andthe residence time of the strands in the aperture. By using a stopperscreen having a series of depressions and elevations arranged in a givenpattern, tufted structures with varying tuft heights corresponding toany desired pattern may be obtained. If desired, suction may be appliedunder the stopper screen in order to aid tuft formation.

Tuft density may be controlled and/or increased by tufting thefilamentary strands into an elastomeric apertured member in thestretched state and subsequently relaxing the apertured member aftertufting has been completed. Alternatively, the filamentary strands maybe tufted into an apertured member composed of a shrinkable material,followed by shrinking the a'pertured' member upon completion of thetufting process. Tuft density may also be increased by using shrinkableand/or crimpable strands as the tuft-forming elements, and subsequentlysubjecting the tufted structure to an after-treatment to effectshrinkingv and/or crimping of the tuft strands. If desired, thefilamentary strands may be tufted into an aperturcd member consisting ofan array of parallel or converging blades, wires or the like, to producestructures consisting of parallel or converging rows of tuft loops. Bythe use of reeds, combs or other means, the individual tuft loops may bemoved closer together or farther apart, while still supported by theaperture'd member, thereby offering an additional method for varyingtuft density.

The filamentary strands may be bonded to the apertured member by avariety of process modifications. Thus, the strands may be heated totemperatures high enough to soften them temporarily so that they becomeanchored to the apertured member during tufting. Alternatively, thestrands may be composed wholly or in part of heat-softenable materials,which are subsequently fused to the apertured member by applying heat tothe back of the tufted structure. A stretched elastic or apost-shrinkable apertured member may be used during tufting and then berelaxed or shrunk to anchor the tufts. Bonding may also be achieved byapplying a resinous binder or adhesive to the back of the tuftedstructure or by depositing fusible fibers, fibrids, binder particles,etc., to the back of the tufted structure, followed by heating to effectbonding.

Dilferent types and/or colored strands may be used in the production ofa single tufted structure, optionally in conjunction with a programmedstrand traverse, to produce tufted structures having a programmedsurface, hand, aesthetics or color pattern.

The tufted structures of this invention may be subjected to variousafter-treatments, such asdyeing, emboss ing, etc'., to produce apatterned or otherwise modified structure.

The tuft loops may be sheared or otherwise cut, either during or afterproduction of the tufted structure, to produce a cut pile surface.

The tufted structures produced by this invention are useful as pileproducts of all types including furs, fleeces, floor coverings, towels,blankets, etc. In addition, they may be used as stuifing materials,padding, filters, liners, etc. Depending on the end use it may bedesirable to apply a permanent backing to one or both sides of thetufted structure.

In the drawings, which illustrate specific embodiments of the process ofthis invention as practiced with various forms of apparatus,

FIGURE 1 is a schematic view of the production of tufts in woven fabric,with the fabric in a horizontal plane during tufting and with thetufting strand fed directly from a spinneret,

FIGURE 2 is schematic view of a modification of the process wherein thetufts are produced as the fabric is woven, and

FIGURE 3 is a schematic View of another modification wherein the fabricis tufted on a revolving drum and the tuft'mg strand is fed from a pirn.

Referring now more particularly to the drawing, FIG- URE 1 illustratesthe preparation of a tufted structure in association with a conventionalspinning operation. Freshly formed filaments 2 emerging from spinneret 1are passed through fluid jet 3 to which a suitable fluid is suppliedunder pressure through inlet 4. A woven fabric, wire screen, or othersuitable aperturcd structure 5 isunwound from roll 6, fed in ahorizontal direction beneath the jet, and is rewound on roll 7. Meansfor maintaining the fabric taut during passage through the tufting zoneare indicated by tension rolls 8 and 9. A tension bar it) may beprovided to apply tension immediately prior to the jet and to guide thefabric in close proximity to the tip of the jet. The jet 3' is locatedso that apertures of the fabric successively intercept the path of thefilaments emerging from the jet. The fluid emerging from the jet thenforces the filaments 2 into and through the apertures to form tuft loops11 suspended from the walls of the apertures. A stopper screen 12 may beplaced below the fabric to help control the tuft height.

While the above illustrates the use of a single jet, it is to beunderstood that a series of jets, preferably arranged so that thefilaments emerging from each jet traverse the walls of a given aperturerow along the center line of the row, may be used for the continuousproduction of tufted products. If desired, an applicator roll, sprayingdevice or the like may be used to apply a binder material to theapertured member before or after its passage through the tufting zone.

If desired, a permanent backing is applied to the tufted. structure atthe end of the tufting zone before the structure iscontinuously wound upinto package '7.

In a variation of the above process, the apertured structure is arrangedto traverse the tufting zone in the manner of a conveyor belt. Uponcompletion of tufting, a permanent backing is continuously applied tothe tufted structure.

FIGURE 2 illustrates tufting during the production of a plain weavefabric. Since the weaving operation is conventional, the loom is shownin greatly simplified form. Warp yarns 20 are fed from left to right.Harness frame 21 raises the odd warp ends while harness frame 22 lowersthe even warp ends. Shuttle 23 is shot through the warp shed between theodd and even warp ends, leaving filling pick 24 in its wake as shown.Harness frames 21' and 22 are then returned'to' the center positionandreed 25 is swung to the right to beat the loose pick into positionasshown at fell 26 of the cloth. The harness frame 21 then lowers the oddWarp ends while harness frame 22 raises the even Warp ends, the shuttleis shot back through the Warp shed and the additional pick is positionedas before.

In accordance with the present invention, tufting jet 27 is alternatelytraversed across and in close contact with the sheet of Warp yarns so asto insert tuft loops- 28 between the warp yarns; The movement of thetufting jet parallels that of the shuttle so that rows of tuft loops areseparated by picks of filling yarn. Movement of the reed as describedabove beats both the picks; and tufts into place in the fabric. When thetufts are inserted while the warp yarns are separated as shown, adouble-tufted fabric is produced having tuft loops profjecting from bothfaces of the fabric as indicated in the enlarged portion within thecircle.

In the process illustrated in FIGURE 3, the apertured structure 30 to betufted is secured tautly about the cylindrical surface of drum 31. Thearea to be tufted is spaced from any surface of the drum and may besupported by vanes or bars which do not impede the insertion of tufts. Apirn 32 is shown for providing the tufting yarn 33, but a strand canobviously be supplied from any convenient source. The yarn 33 passesthrough tension gate 34 to forwarding rolls 35, 36, which may be heatedto soften or plasticize the yarn temporarily. The yarn then passesthrough jet 37 supplied with fluid under pressure at opening 38. Thejetting fluid forces the yarn into apertures of the structure 30 to formtufts. The drum 31 is revolved at suitable speed to form a series oftufts, and the jet 37 is traversed to cover the desired area. Tuftheight may be varied by varying the relative speeds at which the yarn isejected and the drum is revolved. The spacing between the aperturesstructure and the drum surface also affects the tuft height and type,when the drum surface acts as a stopper screen, in the manner discussedpreviously. The tufted structure produced is removed from the drum toprovide an open width tufted product.

In the continuous production of tufted products, a small roller may bearranged to rotate in contact with the apertured structure immediatelybehind the fluid jets in order to prevent the already tufted strandsfrom being pulled out of their respective apertures during tufting ofthe adjacent, succeeding aperttues.

In operating the process of this invention, the fluid jet is arranged sothat its exit is in close proximity to the surface of the aperturedbacking material. When a compressible fluid, such as air, is used, thejet Should be spaced at a distance of less than one inch from theapertured backing material at which the fluid will force the tuftingstrand through the apertures of the backing material. The pressure ofthe fluid admitted to the jet is regulated so as to draw the filamentarystrand into the jet and to drive it therefrom into the apertures of thebacking material. The strand may be fed to the fluid jet at high or lowvelocity, even at a very low velocity, such as by hand. Generally, it ispreferred to combine the tufting process with the production and/ orprocessing of the strand, in which case the strand is fed to the fluidjet at a substantially constant, predetermined velocity. The fluid exitstherefrom at a higher velocity determined by the pressure of the fluidadmitted to the jet.

By varying the process conditions, any size, shape, and type offilamentary strand may be tufted into apertured structures having avariety of cell sizes and shapes providing that the stream of fluid hassuflicient velocity to force the fibers beyond the plane of theapertured structure and that the cell size is at least twice thediameter of the strand. It is to be understood that if an entire strandbundle, e.g., a continuous filament tow, is to be tufted into each cell,the cell size must be at least twice the minimum cross-sectional area ofthe strand bundle. If it is desired to insert only a portion of thetotal number of strand filaments into each cell, the cell size may besmaller. The minimum size of the cell into which a given strand can betufted is dependent not, only on the diameter of the strand but also onits resistance to being bent or doubled upon itself. For higher modulusstrands, which resist bending, it is possible to temporarily reduce thestrand modulus during tufting, for example, by using steam in the jet toheat and plasticize the strand, to permit tufting under conditionsotherwise not possible. Alternatively, it may be suflicient to increasethe fluid velocity.

Preferably, the fluid jet is arranged so that the filamentary strandexiting from it travels in a direction substantially perpendicular tothe apertured backing material. If it is ii desired to insert an entirestrand bundle into each cell of the backing material, the exit orificeof the jet should have a diameter smaller than the cross-sectionaldimension of each cell and is preferably positioned so as to permit theexiting strand to traverse the center line of the cell row.

The tuft-forming strands and/or the process conditions may be varied, asdesired, to produce products having different types of tufts rangingfrom fine, furlike tufts composed of a number of individual filamentloops to dense, discrete tufts composed of a single loop of twisted oruntwisted yarn.

The production of tufted structures by the process of this inventionwill be explained more thoroughly in the following examples.

Example I This example illustrates the tufting of a continuous filamentyarn into cheesecloth.

A 70 denier, 34 filament nylon yarn is led from a supply source througha feed roll and guide system and then into a yarn bulking jet. The jetis of the type disclosed in FIG. 8 of Breen US. Patent No. 2,783,609,issued March 5, 1957, except that the bottom face of the jet is roundedoff to prevent snagging of the jet with the cheesecloth. Air is suppliedto the jet at 90 psi. through a pipe on one side of the jet, and theyarn and air exit vertically from the jet at high velocity from an exitorifice at the bottom of the jet.

A commercial cheesecloth, having a cell size of approximately V inch, ismounted tautly around two power driven wheels in the manner of aconveyor belt and is passed horizontally beneath and in close contactwith the jet exit as illustrated in FIGURE 1.

The high velocity air propels the yarn and forces it into successiveopenings in the cheesecloth thereby forming tuft loops in the cells ofthe cheesecloth as it passes in contact with the jet.

Example 11 This example illustrates a simultaneous tufting and weavingoperation to produce a tightly woven fabric having tuft loops on bothsides thereof.

A. continuous filament yarn is fed into an air jet as described inExample I. Tufting is carried out in conjunction with the weaving of afabric from a 70 denier, 34 filament polyethylene terephthalate yarn ona conventional loom. This is accomplished as illustrated in FIG- URE 2by alternately traversing the jet across and in close contact with thesheet of warp yarns (760 ends) so as to insert tuft loops in theinterstices between successive warp yarns and then allowing the shuttleto insert the next filling yarn. Filling yarns are inserted at picks perinch. Since the tufting yarn is inserted while the warp yarns areseparated into two planes by the motion of the harnesses, the resultingtuft loops project from both surfaces of the woven fabric.

The final product is a tightly woven fabric having a plurality of shorttuft loops projecting from both surfaces and is suitable for use astoweling and the like.

Example 111 This example illustrates the production of a tuftedstructure on an aluminum louvered screen, using steam to propel the yarnthrough the louvers.

Using apparatus of the type shown in FIGURE 3, a 1300 denier, 68filament trilobal nylon carpet yarn is taken from a pirn over heatedfeed rolls and into a crimping jet operating with steam at 200 lbs./ sq.in. pressure.

The exit of the jet is A inch from the surface of a drum having analuminum louvered screen supported so that it will move under the jet ata velocity of 700 feet per minute with the length of the louversparallel to the axis of the drum. The louvers are inch long, inch apart,and are bent to form an angle of 45 with the radius of the drum. The jetprovides tension to pull the yarn off the feed rolls at 5,200 feet perminute and forces the yarn through the openings of the lcuveredstructure to form loops on the underside thereof.

Under these conditions, a high steam pressure is required: to producetufts. At a steam pressure of 100 p.s.i., the tufting yarn does notpenetrate the openings of the louvered structure. At 150 p.s.i.., thetufting yarn penetrates only part way through the louvers. At 200'p.s.i., the yarn goes completely through the louvers to form tuft loopsas previously described.

Example IV This example illustrates the production of a tufted carpetstructure on scrim, using steam to propel the yarn through the openingsof the scrim.

Using apparatus of the type shown in FIGURE 3, a 1300 denier, 68filament trilobal drawn nylon carpet yarn is taken from a pirn overheated feed rolls and into a crimping jet operating with steam at 200lbs/sq. in. pressure. The exit of the jet is inch from the surface of adrum having rug-making scrim with square apertures 7 x inch on /4 inchcenters, supported so that i will move under the jet at a velocity of700 feet per minute with the sides of the squares parallel to thedirection of motion and with the centerline of the openings under thecenterline of the jet. The jet provides tension to pull the yarn off thefeed rolls at a velocity of 5,200 feet per minute. Conditions in the jetform a partial crimp in the yarn, which can later be fully developed byimmersing the finished carpet in boiling water. The high velocity steamissuing from the jet exit forces the yarn through the apertures of thescrim, forming looped tufts inch in height. The fact that the crimp isonly partially developed allows the yarn to pass easily through theapertures. The tufted carpet is subsequently immersed in boiling waterto crimp the filaments more severely and produce a more compact,resilient pile.

Example V This example illustrates the production of a doublesided looppipe on plastic netting.

Using apparatus of the type shown in FlGURE 3, a 1300 denier, 68filament trilobal drawn nylon carpet yarn is taken from a pirn overheated feed rolls and into a crimping jet operating with steam at 150lbs/sq. in. pressure. The exit of the jet is /5; inch from the surfaceof a drum having an 8 mesh plastic netting supported so that it willmove under the jet at a velocity of 70-3 feet per minute with thediagonals of the rhombic apertures of ike netting parallel to thedirection of motion. The yarn is travelling at a velocity of 5,200 feetper minute. During tufting some of the filaments of the yarn passthrough the apertures to form tuft loops on the underside of the net--ting. There is insuflicient force to propel all of the filaments throughthe apertures, but filament loops are formed on the jet side of thenetting. The resulting tufted structure consists of a plastic netting,both sides of which are covered with a resilient loop pile of nylonfilaments, the netting being hidden by the filaments.

Example V I This example illustrates the production of a tuftedstructure on plastic netting wherein individual fibers of each tuft areshared with those of adjacent tufts in all planar directions.

Using apparatus of the type shown in FIGURE 3, a 1300 denier, 68filament trilobal drawn nylon carpet yarn is taken from a pirn overheated feed rolls and into a crimping jetoperating with steam at 2.50lbs/sq. in. pressure. The exit of the jet is inch from the surface ofthe drum having S-mesh plastic netting supported so that it will moveunder the jet at a velocity of 700 feet per minute with the diagonals ofthe rhombic cells of the netting parallel to the direction of motion.Conditions in the jet form a partial crimp in the yarn, which can laterbe fully developed by immersing the finished structure in boiling water.The filaments, travelling at a velocity of 5,200 feet per minute packinto one cell until no more will pass. They are then diverted intoadjacent cells. The diverting of excess filaments into adjacent cells isaided by the tendency of the steam to follow the path of leastresistance. When one cell is filled with filaments, the steam is forcedto flow into neighboring cells carrying filaments with it.-

Since many dflferent embodiments of the invention may be made withoutdeparting from the spirit and scope thereof, it is to be understood thatthe invention is not limited by the specific illustrations except totheextent defined in the following claims.

I claim:

1. A process for producing tufted structures which comprises propellinga filamentary strand by means of a high velocity fluid into contact withan apertured backing material, said fluid having suflicient velocity toforce the strand through openings in the backing material to form tufts,and forming a series of tufts by relative lateral movement bet-ween thestrand and backing material to cause the strand to alternately penetrateopenings in the backing material and suspend itself from the walls ofthe openings, thereby forming tuft loops in each opening.

2. A process as defined in claim 1 wherein said strand is produced andfed directly to the tufting process in a continuous operation.

3. A process as defined in claim 1 wherein said strand is supplied froma yarn package.

4. A process as defined in claim 1 wherein said relative lateralmovement between the strand and backing material is carried out in aprogrammed manner to produce a pattern of tufts.

5. A process as defined in claim 1 wherein the rate of relative movementbetween the strand and backing member is varied to vary the tuftheight.

6. A process as defined inclaim 1 wherein tufts are produced on bothfaces of the backing material.

7. A process as defined claim 1 wherein strands are propelled againstboth faces of the backing material to produce tufts projecting from bothfaces of the backing material.

8. A process as defined in claim I wherein the backing material istraversed with a plurality of propelled strands to produce tufts havingstrands suspended from all walls of each opening, the strands of eachtuft being shared with those of adjoining tufts in the planar directionsof the tufted structure.

9. A process as defined in claim 1 wherein the tuft height is controlledby stopping the strand, after penetration through said openings, againsta stopper surface spaced from the apertured backing material.

10. A process as defined in claim 9 wherein said stopper surface is ascreen.

11. A process as defiined in claim 9 wherein said stopper surface has athree-dimention-al configuration to provide a pattern of tufts varyingin height.

12. A process as defined in claim I0 wherein suction is applied to thestopper screen to aidin tuft formation.

13. A process as defined in claim 1 wherein said apertured backingmaterial is elastomeric, the backing is stretched during tuft formationand is subsequently relaxed to increase the tuft density.

14. A process as defined in claim 1 wherein said apertured backingmaterial is shrinkable and is shrunk after tuft formation to increasethe tuft density.

15. A process as defined in claim 1 wherein said strand is composed ofpost-deformable material and the tufted product is after-treated toincrease the tuft density.

16. A process as defined in claim 1 wherein the openings of saidapertured backing material are slots formed by generally parallelelements, the strand is applied to form tuft loops over the elements andthe loops are subsequently pushed together to increase the tuft density.

17. A process as defined in claim 1 wherein the strand is composed ofthermoplastic material and is softened by heating above room temperatureand below the melting point when propelled into contact with the backingmaterial.

18. A process as defined in claim 1 wherein the tufted structure isproduced in a loom, the apertured backing material is a plurality ofwarp ends being woven into a fabric and the tufts are formed bysuspending the strand over the warp ends to be consolidated into thewoven fabric between picks of filling yarn.

19. A process for producing tufted structures which comprises propellinga filamentary strand by means of a high velocity fluid into contact withan apertured backing material, said fluid having sufiicient velocity toforce the strand through openings in the backing material to form tufts,forming a series of tufts by relative lateral movement between thestrand and backing material to cause the strand to alternately penetrateopenings in the backing material and suspend itself from the Walls ofthe openings, and continuing to propel the strand into contact with thebacking material until both tufts and a randomly entangled strand layerare formed to produce a tufted structure having a backing web composedof strands continuous with tuft strands.

References Cited in the file of this patent UNITED STATES PATENTS2,336,745 Manning Dec. 14, 1943 2,395,136 Millhiser Feb. 19, 19462,712,225 Moore .July 5, 1955 2,815,558 Bartovics et a1 Dec. 10, 19572,884,680 Nowicki May 5, 1959 3,021,698 Hill Feb. 20, 1962 3,030,691 LawApr. 24, 1962 3,039,170 Marshall June 19, 1962 3,055,080 Claussen et alSept. 25, 1962

1. A PROCESS FOR PRODUCING TUFTED STRUCTURES WHICH COMPRISES PROPELLINGA FILAMENTARY STRAND BY MEANS OF A HIGH VELOCITY FLUID INTO CONTACT WITHAN APERTURED BACKING MATERIAL, SAID FLUID HAVING SUFFICIENT VELOCITY TOFORCE THE STRAND THROUGH OPENINGS IN THE BACKING MATERIAL TO FORM TUFTS,AND FORMING A SERIES OF TUFTS BY RELATIVE LATERAL MOVEMENT BETWEEN THESTRAND AND BACKING MATERIAL TO CAUSE THE STRAND TO ALTERNATELY PENETRATEOPENINGS IN THE BACKING MATERIAL AND SUSPEND ITSELF FROM THE WALLS OFTHE OPENINGS, THEREBY FORMING TUFT LOOPS IN EACH OPENING.